Multifunction Heating Process Controller -...

w w w . c e i a . n e tw w w . c e i a . n e tCEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and options, to the prices and conditions of sale

MASTER CONTROLLER V3+Multifunction Heating Process Controller

Feature Highlights

� Programming and management of up to

two independent heating stations, consisting of:

>> CEIA Power Cube Generator

>> CEIA SH/SLE series non-contact

temperature sensor or external

thermocouples

>> automatic solder dispenser

>> antioxidant gas diffuser

� High-definition graphic display

� Internal memory and removable SDC Card

containing up to 100 work programs

� Multiple interface Capability including:

>> Industrial current/voltage I/O

>> Field Bus

>> RS-232

>> up to 22 input and 22 output

� Validation and Reporting of each heating cycle

for Production Quality Control and Certification

� “STATUS” key for immediate reading of main

Generator working parameters

� “QUICK ACCESS” key for fast programming

of user defined parameters

NEW GENERATION

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Multifunction Heating Process ControllerMASTER CONTROLLER V3+

w w w . c e i a . n e t CEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and options, to the prices and conditions of sale

The Master Controller V3+ is a multifunction industrial control

unit, designed for automatic management of programmable

heating processes

For more than 30 years CEIA has been manufacturing Gen-erators and Control units for induction heating processes characterized by very high efficiency and minimum oper-ating costs. CEIA’s unique technological solutions allow the manufacturing of power equipment with compact size, extremely high-energy efficiency and long-term reliability.

Thanks to the experience achieved in the field, and to the continuous R&D activities, CEIA is now proud to intro-duce the Master Controller V3+.

The Standard Controller version comes with a set of predefined programs. All operating parameters for each phase of the heating cycle can be programmed within a wide range of values.

This allows maximum flexibility in setting the heat-ing and cooling times, the power supplied by the induc-tion generators, the operating temperatures for the piece being worked on and the quantity and feed speed of the soldering wire.

A wide range of digital and analog I/O signals, a fieldbus and an RS-232 serial interface allow connection to PLC, PC or external logic for remote loading and running of pre-set and user-defined heating programs.

The isolated inputs have programmable P/N logic, while the isolated outputs use a programmable auxiliary voltage of 12/24 V.

The main programming parameters of the two heating stations are shown on the display of the CEIA Master Controller. A bar-graph Indicator shows the correct matching of the inductor. Changes in operating conditions, such as load variations, are displayed in real time.

A service menu, accessed by pressing the STATUS key, displays a summary of the internal generator operating parameters

HIGH-DEFINITION GRAPHIC DISPLAY

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Thermal Profile Control

Field Bus Interface

Compact Pyrometers (2)

Web Server & Data Logger

Wire Feeder Dispensers (2) Anti-Oxidizing Gas Diffuser (2)

Thermo Camera Control

Power Cube Generator (2)

w w w . c e i a . n e tCEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and options, to the prices and conditions of sale

Advanced Control and Interface Functions

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Real-time Thermal Profile screen, combined with Web server and Data Log option

Thermal Profile Management and Monitoring

� Up to 20 Programmable Temperature and Time Segments per Process

� Up to 100 different storable processes

� Maximum Power Output Programmable for Each Individual Segment

� Temperature Tolerance Window Programmable for Each Individual Segment

� Out-of Tolerance and End-of-Cycle Outputs for Each Process

Thanks to the Thermal Profile Monitoring software, coupled with the new CEIA SH15/SLE Optical Pyrometers, the user is now able to set specific temperature profiles, monitor and certify the heating process of each production item.

Integrated Web server and Data Log System

Data Logger screen

� Integrated Webserver with 2-port 100base-T Ethernet switch

� No client software required, only a web browser

� Zero configuration network for simple setup

� Built-in Rich Internet Application (RIA) for Status Monitoring, Remote Programming, Logging and Thermal Profile Management

� Internal storage capacity for more than 100.000.000 data samples

The Master Controller V3+ is equipped with integrated Data Log and Web Server system. It is possible to perform auto-matic data storage, for a proper process quality control, monitoring heating temperatures, output power, frequency, volt-age and inductor current.

An Ethernet TCP/IP port allows access to the internal web server of the Master Controller for remote programming set-tings and interface with SCADA / DCS systems.

5w w w . c e i a . n e tCEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and options, to the prices and conditions of sale

Wire Feeder Control

� Control up to two independent Wire Feeders, one for each heating station

� Control parameters:

>> Quantity and speed of wire feeding

>> Quantity and speed of wire rewind

>> Activation time of alloy feeding

>> Wire feeding motor torque

>> Wire presence sensor

Tin Soldering Control

� Optimized version for tin soldering

� Same features as the wire feeder control with the added special features

Special Features

� Management of the automatic use of two wire feeders on the same piece to braze.

� Management of emissivity change (emissivity A and B) during the heating process

� Management of the brazing process without temperature control (heating time and two levels of programmable power)

� Management of the automatic use of two Wire Feeders on the same piece to braze, during the working mode “Thermal Profile” (only if the TP option is active).

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CEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and options, to the prices and conditions of salew w w . c e i a . n e t

Field Bus Management

� Management and control of the heating process via Field Bus protocol:

>> Profinet

>> EtherCAT

>> EtherNet / IP

>> Others upon request (DeviceNet, Profibus, CANopen, CC-Link, CompoNet, ControlNet, Modbus-RTU or TCP, SERCOS III)

� Main Master Controller functions managed:

>> Start / Stop cycle

>> Abort / Reset cycle

>> Set Point Power

>> Temperature measured in real time

>> Set Point Temperature

>> Power output in real time

>> Thermal profile step in progress

>> Generator diagnosis

� Field Bus and Network compliance certification available upon request

Thermocamera Control

� Interface with Thermocamera via a direct Ethernet connection on the Master Controller v3+

� Management of up to two independent zones of interest (ROI # 1 and ROI # 2).

� Ideal for temperature control on large surfaces or in applications where the location of the hot spot moves during the heating process (Max Temperature Spot Automatic Tracking)

� Simultaneous measurement and control of two different areas used to prevent over heating

7CEIA reserves the right to make changes, at any moment and without notice, to the models (including

programming), their accessories and options, to the prices and conditions of sale w w w . c e i a . n e t

Model Configuration

OPTIONS Code

WIRE FEEDER CONTROL Management of two independent wire feeders (one for each soldering point) V3+/WF

THERMAL PROFILE CONTROL Thermal profile working mode V3+/TP

ETHERNET BOARD INTERFACE Web Server & Data Logger V3+/IXC

ETHERCAT FIELD BUS INTERFACE V3+/FB -ETHERCAT

PROFINET FIELD BUS INTERFACE V3+/FB-PROFINET

ETHERNET/IP FIELD BUS INTERFACE V3+/FB-ETHERNET/IP

TIN SOLDERING CONTROL Version optimized for Tin Soldering. Includes the V3+/WF option V3+/TS

THERMOCAMERA CONTROL Includes the V3+/IXC option V3+/DIAS

BASE UNIT Code

MASTER CONTROLLER V3+ MASTER-C-V3+

ACCESSORIES Code

PROGRAM CARD SDC Card to save / load up to 100 work programs 55265

CONTROLLER TO OPTICAL PYROMETER CONNECTION CABLE

1,5 m length 49438

4 m length 49439

WIRE FEEDERS

0.3 to 0.65 mm silver wire feeder PW3-WF/0.5

0.7 to 1.1 mm silver wire feeder PW3-WF/1

0.8 to 1.2 mm tin wire feeder PW3-WF/ST1

1.3 to 1.7 mm tin wire feeder PW3-WF/S1,5

GAS DIFFUSERS

Anti-Oxidizing gas diffusion system SG100

Cooling and Anti-oxidizing gas diffusion system SG101

ACTIVATING PEDAL 1,5 m 3457

4 m 46059

RS-232 CABLES

RS-232 cable (M-F) for the connection between the Controller and the Generator (1 m length)

19623

RS-232 cable (M-F) for the connection between the Controller and the Generator (3 m length)

23243

RS232 cable (F-F) for the connection between the Controller and a Computer (3 m length)

50086

8 w w w . c e i a . n e t CEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and options, to the prices and conditions of sale

Compact Optical PyrometersSH/SLE

SH/SLE Compact Optical Pyrometers

CEIA offers a wide range of infrared optical sensors, equipped with low-intensity LED aiming, which covers an operating temperature range from 80°C to 2200°C.

The SH/SLE sensors allow high quality management of the heating process according to the set temperature values. The reduced overall dimensions allow an easy integration of the pyrometer in automatic production systems. Up to two optical sensors for temperature measurement can be connected to the generator.

Compact Pyrometers for Measurement of metallic surfaces between 80°C and 2200°C

SH/SLE series

Features

>> SH15/SLE Single-color Series

80°C to 2000°C

>> SH2C/SLE Dual-color Series

600°C to 2200°C

� Emissivity adjustable from 0.1 to 1 (SH15/SLE series)

� Temperature measurement independent from metal emissivity (SH2C/SLE series)

� High Accuracy

� High-Speed

� Very Compact design

� Available with different focus distance and aiming spot size

� LED aiming light

� Supplied with Calibration Report traceable to Certified International Standards

� AISI 304 Stainless Steel Construction


SH/SLE Pyrometers Selection

Specifications

MODEL TEMPERATURE RANGE

SH15/SLE-550-D1 80... 700°C

SH15/SLE-550-D2 120... 900°C

SH15/SLE-550-D3 200... 1600°C

SH15/SLE-550-D4 500... 2000°C

SH2C/SLE 300... 2200°C

CEIA SH/SLE Pyrometer mounted on ES3M micrometric optical sensor base

SH15/SLE SH2C/SLESingle-color mode Dual-color mode

TEMPERATURE RANGE 80... 2000°C 300... 2200°C 600... 2200°C

TEMPERATURE RESOLUTION 0.1 °C (up to 999.9 °C)1 °C (above 1000 °C)

0.1 °C (up to 999.9 °C)1 °C (above 1000 °C)

0.1 °C (up to 999.9 °C)1 °C (above 1000 °C)

EMISSIVITY RANGE 0.1-1.0 0.1-1.0 N/A

READING SPOT DIAMETER see table see table see table

FOCUS DISTANCE see table see table see table

RESPONSE TIME 100 uS Time Constant

UNCERTAINTY ± 0,3% of reading in °C. All Pyrometers are supplied with calibration report traceable to certified International Standards

MEASUREMENT SPOT AIMING High Definition, 620 nm wavelength led beam

INTERNAL DIGITAL CONTROLS Offset and Range Calibration Parameters

Environmental Temperature Measurement and Correction

Automatic Gain Range Selection

POWER SUPPLY +/-15 V - +10/-5 mA, directly supplied by CEIA Controllers

CONNECTION CABLE Diameter 4.8 mm x Length 5 ... 1.5 ... 4 m

HOUSING AISI 304 Stainless Steel

WEIGHT 100 g

HOUSING PROTECTION CLASS IP65

OPERATING TEMPERATURE 0 °C to + 65 °C

STORAGE TEMPERATURE - 25 °C to + 70 °C

CONFORMITY Complies with international standards currently applicable for Electrical Safety and Electromagnetic Compatibility (EMC)

10 w w w . c e i a . n e t CEIA reserves the right to make changes, at any moment and without notice, to the models (including programming), their accessories and options, to the prices and conditions of sale

Compact Optical PyrometersSH/SLE

Model Configuration and Optics Data

MODEL Close-up lens

Ddistance (mm)

Spot diameter (mm)

D1distance 1 (mm)

Spot 1 diameter (mm)

D2distance 2 (mm)

Spot 2 diameter (mm)

SH15/SLE-550-D1

80... 700°C

Included 550 12.5 1000 36 2000 86

CL240/SH15 240 4.5 500 24 1000 63

CL120/SH15 120 2.5 250 19 500 52

CL60/SH15 60 0.5 150 18.5 300 51

SH15/SLE-550-D2

120... 900°C

Included 550 4.5 1000 21 2000 57

CL240/SH15 240 1.5 500 18 1000 51

CL120/SH15 120 1 250 17 500 46

CL60/SH15 60 < 0.4 150 19 300 50

SH15/SLE-550-D3

200... 1600°C

Included 550 2 1000 16.5 2000 47

CL240/SH15 240 0.6 500 16 1000 47

CL120/SH15 120 < 0.4 250 15 500 44

SH15/SLE-550-D4

500... 2000°C

Included 550 2 1000 16.5 2000 47

CL240/SH15 240 0.6 500 16 1000 47

CL120/SH15 120 < 0.4 250 15 500 44

SH2C/SLE

300... 2200°C

Included 550 12.5 1000 36 2000 86

CL240/SH15 240 4.5 500 24 1000 63

CL120/SH15 120 2.5 250 19 500 52

FOCUS DISTANCE (mm)

D0

spotspot1

spot2

D1 D2

TYPICAL APPLICATIONS

SH2C/SLE modelSH15/SLE model

∫ ANNEALING

∫ BONDING

∫ BRAZING

∫ CAP SEALING

∫ CURING

∫ FORGING

∫ HARDENING

∫ HOT FORMING

∫ LOCALIZED HEATING

∫ MELTING

∫ METAL GLASS SEALING

∫ NORMALIZING

∫ PREHEATING

∫ SINTERING

∫ SHRINK FITTING

∫ TEMPERING

∫ TIN SOLDERING

∫ HARDENING, FORGING, BRAZING, SOLDERING

∫ NOBLE METALS MELTING AND PURIFYING

∫ WIRE/ROD MILL

∫ SILICON PROCESSING

∫ GLASS INDUSTRY - GOB TEMPERATURE MEASUREMENT

∫ CEMENT INDUSTRY - CLINKER TEMPERATURE IN ROTARY KILNS


ACCESSORIES Description Focus distance Code

CLOSE-UP LENS SH15-FOCUS

240 mm CL240/SH15

120 mm CL120/SH15

60 mm CL60/SH15

COOLING JACKET UNIT WITH INTEGRATED AIR PURGE SLE-PURGE-COOL

90° VIEW MIRROR SYSTEM SLE-90D-BD

AIR PURGE UNIT SLE-PURGE

CONNECTION CABLE

Length: 1.5 m 49438

Length: 4 m 49439

ES3M MICROMETRIC OPTICAL SENSOR BASE 23497

SH23 OPTICAL SENSOR BASE 21871

DIMENSIONS

Pyrometer Additional lens

2.6 mm

20 mm

5 mm 10 mm

5 mm

20 m

m

15 m

m

M19

x1

M19

x1

M19

x1

137 mm

145 mm

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MASTER CONTROLLER V3+


DP040K0014v2000UK-67323

COSTRUZIONI ELETTRONICHE INDUSTRIALI AUTOMATISMI

Zona Ind.le 54/G, 52041 Viciomaggio - Arezzo (ITALY)Tel. +39 0575-4181 Fax +39 0575-418287 E-mail: [email protected]

HEATING SYSTEM SET-UP

Alternating between the two heads (if connected to a single Power Cube generator)Simultaneously on two heads (if connected to two Power Cube generators)Capable of driving Power Cube generators in continuous operation

MANAGEMENT AND CONTROL

Activation of cycle: via external contact, RS-232 or Fieldbus interfaceControl and Time Programming of 2 antioxidant gas diffusers, 2 heating heads and 2 wire dispensersAvailable Settings: heating power; heating temperature (resolution 0,1°C); wire quantity and speed; antioxidant gas supply times; maximum solder force; wire feeder; piston advance delayControl of the temperature of the article being processed: via optical temperature sensors, thermocouple or external sensorsSH15/SLE sample rate: 0.5 millisecondsSH15/SLE time constant: 0.1 milliseconds

FUNCTIONING MODES

ManualTIMER A: fully time-programmable cycle phases with controlled-temperature holding timeTIMER B: fully time-programmable cycle phases with programmable heating time and optional temperature controlTIMER C: fully time-programmable cycle phases, heating programmable with two times and two power levelsSYNCHRONISED: as TIMER A with holding time synchronised by an external eventFULL AUTO: as TIMER A, with management of the automatic solder wire feederFULL AUTO 2 WIRES: as Full auto, with the possibility of applying two independent solder wire feeders at the same soldering point (available only with –TS option)THERMAL PROFILE: functioning with thermal profile (available only with -TP option)THERMAL PROFILE 2 WIRES: as THERMAL PROFILE, with the possibility of applying two independent solder wire feeders at the same soldering point (available only with –TS and -TP option)

CONTROL INPUTS 2 inputs for the connection of CEIA optical temperature sensors 1 plug for a Field Bus module (accessory)2 insulated digital inputs for connecting the cycle activation pedals 6 insulated auxiliary digital inputs2 insulated digital inputs for halting the operating cycle 2 solder wire dispenser encoder inputs4 0-10V (or 0-20 mA, or 4-20mA) inputs (2 used for power control and 2 for temperature control)

2 “wire present” inputs

2 insulated inputs (RS232) for connection to external programmable units 2 insulated digital inputs for starting a special cycle in manual mode

OUTPUTS FOR ACTIVATION OF EXTERNAL SLAVE DEVICES

2 serial outputs for connecting and managing two independent Power Cube generators 2 output for system ready signal (relay output)2 outputs for activation of antioxidant gas diffusers 2 0-10V (or 0-20 mA, or 4-20mA) outputs for temperature reading2 outputs for “Generator ON” signals 2 0-10V (or 0-20 mA, or 4-20mA) outputs for power reading2 outputs for “Temperature reached” signals 2 solder wire dispenser driver outputs2 outputs for activation of rapid cooling gas diffusers 2 auxiliaries open collector outputs2 outputs for “End of cycle” signals

SELF-DIAGNOSIS Check of temperature and on the cooling water presence Power Cube missed connectionCorrect inductor dimensioning check Generators parameter screenshotInternal malfunction Supply voltage too lowWorking cycle malfunction Supply voltage too highReading/writing malfunction of internal memory cells Soldering wire presenceInductor short circuit Phase missing (if connected to 90, 180, 360 and 720 Power Cube

Generators)Reading/writing malfunction of Program Card memory cells Programming access control through a password

INTERNAL MEMORY 100 sets of working parameters100 different storable thermal processes made of up to 20 segments per process (TP versions)

REMOVABLE DATA FLASH CARD

100 sets of working parameters storable on each card100 different storable thermal processes made of up to 20 segments per process (TP versions)

POWER SUPPLY AND POWER

Power supply voltage: 195-255 Vac, 1~ 50/60 HzMaximum absorbed power: 60 W

OPERATING CONDITIONS

Operating temperature: + 5 to + 55 °CStorage temperature: - 25 to + 70 °C / Relative humidity: 0-95% (without condensation)

CONTAINER Stainless steel constructionDimensions (WxDxH): 275 mm x 265 mm x 140 mm / Weight: 6 kg

SAFETY FEATURES Insulation from the mains voltageLow operating voltage; no risk for the operatorComplies with international standards currently applicable for Electrical Safety (EN 60204-1) and Electromagnetic Compatibility (EN 61000-6-2, EN 61000-6-4)

Technical Data

Multifunction Heating Process Controller -...

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